Folder with filler sheets fixed thereto and method for making same



June 33. 1967 R H. MELLER 3,3243% FOLDER WITH FILLER snmzcrs FIXEDTHERETO AND METHOD FOR MAKING SAME Filed April 7, 1964 INVENTOR.

United States Patent 3 324,918 FOLDER WITH FILLER SHEETS FIXED THERETOAND METHOD FOR MAKING SAME Robert H. Miller, 5415 Grand Ave., WesternSprings, Ill. 60558 Filed Apr. 7, 1964, Ser. No. 358,918 4 Claims. (Cl.15039) This invention relates generally to folders having filler sheetstherein and the method for making the same, and, more particularly, tofolders having fused cover sheets of one material and filler sheets of asecond material.

Conventional folders having filler sheets presently available and usedfor holding papers, documents, brochures and the like, range from largebulky ring type units to plastic carrying cases having covers sealedtogether but whose filler sheets are fastened to the plastic case bysome cumbersome, costly mechanical fastening means, The ring type units,while in most instances durable enough, are in many instances too bulky.When mechanical fastening means are used to retain filler or loose leafsheets in the folder, the fastening means are frequently visible to aperson viewing the folder when it is in a closed or locked position. Asa result, many of the conventional filler sheet folders are deficientdue to the undesirable appearance of the fastening means.

Moreover, using metal rings and other mechanical fastening means tomaintain the tiller sheets in a fixed position within the foldersincreases the cost of the overall unit due to additional steps requiredin the assembly of the folders and their filler sheets. Further, becauseof the cost of fastening means presently used, the overall constructioncost of a folder is increased.

T o obviate these deficiencies I have invented a compact folder whichnot only enhances the overall appearance of the folder but additionallyreduces the unit cost due to the reduction of materials and assemblytime required to make my novel folder.

In my invention, an inner cover is slit at several cations to provide atleast one strip in the inner cover. Filler sheets, generally made from adifferent material than the cover, and having a plurality of apertureslocated in the sheet, are inserted between the strip and cover until theapertures are located beneath the strip and then an outer cover is fusedto both the edges of the inner cover and to the strip. Positionedbetween the inner and outer covers are a plurality of stiffener memberswhile a conventional lock mechanism is attached to the folder forpositively maintaining the folder in a closed position. Because of thefusing operation, fastener means heretofore used are eliminated. At thesame time I have provided a durable unit in that the filler sheets arepermanently maintained in position, Further, with the elimination ofconventional fastener means, the time for assembling a folder with itsfiller sheets is substantially reduced effecting a reduction in the unitconstruction cost.

If it is desired to have a heavy duty folder having an abundance offiller sheets over and above what is normally required, a fasteningmeans, e.g., threaded fastener or the like, can be used for retainingthe sheets in a fixed position in addition to the fusing operation.However, as opposed to conventional devices, the additional fasteningmeans used in my invention is not visible to an individual when a folderis viewed in a closed position.

A further feature of my invention which enables me to reduce the overallconstruction cost of the folder is the use of a unitary stiffener memberwhich is slotted at desired locations along the length or width of themember. This slotted stiffener member can be used in the assembly of afolder in such manner that no additional stiffener members are required.The advantage of this is apparent in that the step of adding a pluralityof stiffener members is eliminated thus further serving as a reductionin construction cost.

Other features and advantages are inherent in the construction claimedand disclosed which will be apparent to those skilled in the art fromthe following detailed description in conjunction with the accompanyingdrawings wherein:

FIGURE 1 is a perspective view of an assembled case having filler sheetsfixedly attached thereto;

FIGURE 2 is a view showing filler sheets separated from the inner coverprior to final assembly;

FIGURE 3 is a fragmentary view showing filler sheets inserted betweenthe inner cover and strip;

FIGURE 4 is a fragmentary view showing filler sheets positioned betweenthe strip and cover follOWing the fusing or sealing operation; and

FIGURE 5 shows a cutaway of FIGURE 1 illustrating the stiffening memberspositioned between the inner and outer covers.

In FIGURE 2, inner cover 10, generally made of a vinyl material, is slitat 11 and 12 to form strip 13 which, as seen for example in FIGURE 2, issubstantially longer in length than in width. Slits 11, 12 do not cutacross the entire length of cover 10 but stop a short distance from eachedge of cover 10. One or more filler sheets 14 having a plurality ofapertures 15, generally located centrally of the filler sheets, areinserted between strip 13 and cover 10 until apertures 15 are locatedbeneath strip 13, as illustrated in FIG- URE 3. The filler sheets, whichact as envelopes for holding cards and the like, are ordinarily made ofpolyethylene or polyurethane, although, if desired, the sheets could bemade of the same material as cover 10. Stiffener members 16 are thenplaced on cover 10 opposite the face upon which filler sheets 14 aresituated and an outer cover 17, made of the same material as inner cover10, is fused to cover 10 at the outer edges of the respective covers.Additionally, the covers are fused to one another near the location ofslits 11 and 12 forming sealing edges 18 and 19. This sealing serves toretain stiffening members 16 in position. To maintain filler sheets 14in a fixed position, strip 13 is fused to outer cover 17 as shown at 20in FIGURE 4 where the fusing of strip 13 to cover 17 occurs within thearea of the respective apertures 15.

The method for assembling the folder having the filler sheets fixedthereto, is shown in FIGURE 2 and comprises the steps of insertingfiller sheets 14 between strip 13 and cover 10. Cover 10 is then placedin a die with the cover face up or on top of filler sheets 14. Stiffenermembers 16 are then positioned on top of cover 10 at desired locationsafter which outer cover 17 is placed on the stiffeners 16. The coversare then fused together with the use of a conventional heat sealing orelectronic fusing machine. Upon removal of the completed case from thedie, a conventional lock device 27 is attached to the case to lock it ina closed position.

Though in most instances the inner and outer covers and strips are madeof the same material and the filler sheets are made of a differentmaterial, it is to be appreciated that the filler sheets and coverscould be made of the same material. Generally the covers are made ofvinyl whereas the filler sheets are made of polyethylene orpolyurethane.

The foregoing detailed description has been given for clearness ofunderstanding only, and no unnecessary limitations should be understoodtherefrom, as modifications will be obvious to those skilled in the art.

3 What is claimed is: 1. The method of forming a folder having at leastone filler sheet fixed thereto according to the steps of:

slitting an inner cover made from a first material to form at least onestrip in said cover;

inserting at least one filler sheet made from a second material andhaving a plurality of apertures therein between said strip and saidinner cover until said apertures are covered by said strip;

placing a plurality of stiffener members adjacent said inner cover; and,

fusing an outer cover made from said first material to said inner coverand said strip through said apertures in said strip.

2. A folder having filler sheets fixed thereto, said folder comprising:

an outer cover made of a first material;

an inner cover made of said first material, said inner cover having apair of substantially parallel slits located therein for a substantialportion along the length of said inner cover thereby forming an integralstrip on said inner cover, said inner cover having a pair ofsubstantially parallel inner edge portions corresponding to saidparallel slits;

said strip formed in said inner cover being substantially longer inlength than in width;

at least one filler sheet made of a second material, said filler sheethaving a plurality of spaced apertures located along the length of saidfiller sheet;

said filler sheet positioned between said inner cover and said integralstrip whereby said apertures in said sheet are positioned completely behind said strip;

stiffening members located between said first and second covers;

said covers being fused together along the respective marginal edges ofsaid inner and outer covers;

at least part of each of said inner edge portions being fused to saidouter cover to positively position said stiffening members; and,

said integral strip of the inner cover being fused to said outer coverwithin the area of said apertures whereby said filler sheet is fastenedto said folder.

3. A folder in accordance with claim 2 wherein said first material isvinyl and said second material is polyethylene.

4. A folder in accordance with claim 2 further including a locking meansconnected to said outer cover for maintaining said folder in a closedposition,

References Cited UNITED STATES PATENTS 2,486,330 10/1949 Schade 281 -292,657,726 11/1953 Silverman 30 2,678,673 5/1954 Sheils 150--39 2,911,02411/1959 Miceli -51 X 3,019,486 2/1962 Stinson 281 21 X 3,146,816 9/1964Osher l5039 3,190,678 6/1965 Peterson et al 281--29 FOREIGN PATENTS1,280,663 11/ 1961 France.

682,075 10/1939 Germany.

687,249 1/1940 Germany.

FRANKLIN T. GARRETT, Primary Examiner.

JOSEPH R. LECLAIR, Examiner.

M. L. MINSK, Assistant Examiner.

Dedication 3,324,918.-R0bert H. Miller, Western Springs, I11. FOLDERWITH FILLER SHEETS FIXED THERETO AND METHOD FOR MAKING SAME. Patentdated June 13, 1967. Dedication filed Aug. 20, 1968, by the assignee, Major Plastics, I no. Hereby dedicates t0 the Public the remaining termof said patent.

[Oflicial Gazette September 24, 1.968.]

1. THE METHOD OF FORMING A FOLDER HAVING AT LEAST ONE FILLER SHEET FIXEDTHERETO ACCORDING TO THE STEPS OF: SLITTING AN INNER COVER MADE FROM AFIRST MATERIAL TO FORM AT LEAST ONE STRIP IN SAID COVER; INSERTING ATLEAST ONE FILLER SHEET MADE FROM SECOND MATERIAL AND HAVING A PLURALITYOF APERTURES THEREIN BETWEEN SAID STRIP AND SAID INNER COVER UNTIL SAIDAPERTURES ARE COVERED BY SAID STRIP;